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M1500/120 GB

Wacker Neuson M1500/120 GB, M1500/230 EU, M2500/120 GB, M2500/230 EU User manual

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Operator’s manual
Drive motor M1500, M2500
for modular internal vibrator HMS
03.2015
5100013660en / 01
Manufacturer
Wacker Neuson Produktion GmbH & Co. KG
Preußenstraße 41
80809 München
www.wackerneuson.com
Tel.: +49-(0)89-354 02-0
Fax: +49-(0)89-354 02-390
Translation of the original operator's manual in German
5100013660IVZ.fm 3
1 Foreword ....................................................................................................................5
2 Introduction ...............................................................................................................6
2.1 Means of representation for this operator's manual....................................................... 6
2.2 Wacker Neuson representative...................................................................................... 7
2.3 Described machine types............................................................................................... 7
2.4 Identification of the machine .......................................................................................... 8
3 Safety .........................................................................................................................9
3.1 Policy.............................................................................................................................. 9
3.2 Qualification of the operating personnel....................................................................... 12
3.3 Protection equipment................................................................................................... 13
3.4 Transport...................................................................................................................... 14
3.5 Operational safety........................................................................................................ 14
3.6 Safety when operating hand-held equipment............................................................... 17
3.7 Safety when operating electrical equipment ................................................................ 17
3.8 Safety when operating modular internal vibrators........................................................ 19
3.9 Maintenance................................................................................................................. 20
4 General Power Tool Safety Warnings ...................................................................21
5 Safety and information labels ................................................................................25
6 Standard package ...................................................................................................26
7 Setup and function .................................................................................................27
7.1 Application.................................................................................................................... 27
7.2 Application area ........................................................................................................... 27
7.3 Mode of operation........................................................................................................ 27
8 Components and operator's controls ...................................................................28
8.1 Components and operator's controls of the drive motor.............................................. 28
8.2 Components of the HMS.............................................................................................. 29
8.3 Components of the flexible shaft (optional).................................................................. 30
8.4 Components of the vibrator head (optional)................................................................. 30
9 Transport, entire system (HMS) .............................................................................31
10 Assembly of the HMS .............................................................................................32
10.1 Pre-assemble the vibrator head................................................................................... 32
11 Operation .................................................................................................................34
11.1 Before commissioning.................................................................................................. 34
11.2 Commission ................................................................................................................. 35
11.3 Decommissioning......................................................................................................... 38
Inhalt
4
5100013660IVZ.fm
12 Maintenance ............................................................................................................40
12.1 Qualification of the maintenance personnel ................................................................. 40
12.2 Maintenance schedule.................................................................................................. 41
12.2.1 Drive motor...................................................................................................... 41
12.2.2 HMS................................................................................................................. 42
12.3 Maintenance work ........................................................................................................ 42
12.3.1 Clean HMS...................................................................................................... 43
12.3.2 Drive motor...................................................................................................... 44
12.3.3 Flexible shaft ................................................................................................... 45
12.3.4 Vibrator head................................................................................................... 48
13 Troubleshooting ......................................................................................................50
14 Permissible combinations .....................................................................................51
14.1 Drive motor – Flexible shaft – Vibrator head................................................................ 51
15 Disposal ...................................................................................................................53
15.1 Disposal of waste electrical and electronic equipment................................................. 53
16 Accessories .............................................................................................................54
16.1 Special wrench for the flexible shaft............................................................................. 54
16.2 Pipe thread seal............................................................................................................ 54
16.3 Special lubricant for the flexible shaft........................................................................... 54
16.4 Shoulder strap for drive motor...................................................................................... 54
17 Technical data .........................................................................................................55
17.1 Drive motor................................................................................................................... 55
17.2 Flexible shaft-E (optional)............................................................................................. 57
17.3 Flexible shaft-S (optional)............................................................................................. 57
17.4 Vibrator head standard (optional)................................................................................. 58
17.5 HA-Vibrator head (optional).......................................................................................... 59
17.6 Extension cable............................................................................................................ 60
18 Glossary ...................................................................................................................62
EC Declaration of Conformity ................................................................................65
DIN EN ISO 9001 certificate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
1 Foreword
100_0000_0002.fm 5
1Foreword
This operator's manual contains information and procedures for the safe opera-
tion and maintenance of your Wacker Neuson machine. In the interest of your
own safety and to prevent accidents, you should carefully read through the safety
information, familiarize yourself with it and observe it at all times.
This operator's manual is not a manual for extensive maintenance and repair
work. Such work should be carried out by Wacker Neuson service or authorized
specialists.
The safety of the operator was one of the most important aspects taken into con-
sideration when this machine was designed. Nevertheless, improper use or in-
correct maintenance can pose a risk. Please operate and maintain your Wacker
Neuson machine in accordance with the instructions in this operator's manual.
Your reward will be troublefree operation and a high degree of availability.
Defective machine parts must be replaced immediately!
Please contact your Wacker Neuson representative if you have any questions
concerning operation or maintenance.
All rights reserved, especially reproduction and distribution rights.
Copyright 2015 Wacker Neuson Produktion GmbH & Co. KG
No part of this publication may be reproduced in any form or by any means, elec-
tronic or mechanical, including photocopying, without the expressed written per-
mission of Wacker Neuson.
Any type of reproduction, distribution or storage on data media of any type and
form not authorized by Wacker Neuson represents an infringement of copyright
and will be prosecuted.
We expressly reserve the right to make technical modifications – even without
special notice – which aim at further improving our machines or their safety stan-
dards.
2 Introduction
6
100_0000_0003.fm
2 Introduction
2.1 Means of representation for this operator's manual
Warning symbols
This operator's manual contains safety information of the categories:
DANGER, WARNING, CAUTION, NOTICE.
They should be followed to prevent danger to life and limb of the operator or dam-
age to equipment and exclude improper service.
Notes
Note: Complementary information will be displayed here.
DANGER
This warning notice indicates immediate hazards that result in serious injury or
even death.
Danger can be avoided by the following the actions mentioned.
WARNING
This warning notice indicates possible hazards that can result in serious injury
or even death.
Danger can be avoided by the following the actions mentioned.
CAUTION
This warning notice indicates possible hazards that can result in minor injury.
Danger can be avoided by the following the actions mentioned.
NOTICE
This warning notice indicates possible hazards that can result in material dam-
age.
Danger can be avoided by the following the actions mentioned.
2 Introduction
100_0000_0003.fm 7
Instructions
This symbol indicates there is something for you to do.
1. Numbered instructions indicate that you have to carry out something in a de-
fined sequence.
This symbol is used for lists.
2.2 Wacker Neuson representative
Depending on your country, your Wacker Neuson representative is your Wacker
Neuson service, your Wacker Neuson affiliate or your Wacker Neuson dealer.
You can find the addresses in the Internet at www.wackerneuson.com.
The address of the manufacturer is located at the beginning of this operator's
manual.
2.3 Described machine types
This operator's manual is valid for different machine types from a product range.
Therefore some figures can differ from the actual appearance of your machine.
It is also possible that the descriptions include components which are not a part
of your machine.
Details for the described machine types can be found in the chapter Technical
data.
2 Introduction
8
100_0000_0003.fm
2.4 Identification of the machine
Nameplate data
The nameplate lists information that uniquely identifies your machine. This infor-
mation is needed to order spare parts and when requesting additional technical
information.
Enter the information of your machine into the following table:
Item Designation Your information
1 Group and type
2 Construction year
3 Machine no.
4 Version no.
5 Item no.
3 Safety
100_0101_si_0005.fm 9
3 Safety
3.1 Policy
In keeping with the latest technological developments
The equipment is built in keeping with the latest technological developments and
according to the recognized technical safety rules. Nevertheless, improper use
can result in hazards to life and limb of the user or third parties or to damage to
the equipment and other material assets.
Use in accordance with the intended purpose
The equipment may only be used for the operation of flexible shafts and vibrator
heads.
The equipment may only be combined with permissible components.
The equipment may only be operated with flexible shafts and vibrator heads per-
mitted by Wacker Neuson.
The equipment may not be used for the following purposes:
The connection of non-permissible components.
Operation without a flexible shaft and vibrator head.
Other special applications must be tested and released by Wacker Neuson.
Use in accordance with the intended purpose also includes the observation of all
notes in this operator's manual as well as complying with the prescribed care and
maintenance instructions.
Any use that exceeds or is not in accordance with the intended purpose is con-
sidered improper The manufacturer's liability and warranty are canceled for any
damage resulting from improper use. The risk lies entirely with the operator.
3Safety
10
100_0101_si_0005.fm
Structural changes
Do not carry out any structural changes without written approval from the manu-
facturer. You will thereby be endangering your safety and the safety of others!
Additionally, the manufacturer's liability and warranty will be canceled.
In particular, the following cases are considered structural changes:
Opening the device and permanent removal of components that originate
from Wacker Neuson.
Installing new components that do not originate from Wacker Neuson or are
not comparable in the design system and quality of the original parts.
Attaching accessories that do not originate from Wacker Neuson.
You can safely install spare parts that originate from Wacker Neuson.
You can safely attach accessories that are available for your equipment in the
Wacker Neuson product range. To do so, please refer to the attachment regula-
tion in this operator's manual.
For example, do not drill into the housing to attach signs. Water can enter into
the housing and damage the equipment.
Prerequisite for operation
The flawless and safe operation of the equipment requires the following:
Proper transport, storage and assembly.
Careful operation.
Careful care and maintenance.
Operation
Only operate the equipment in accordance with the intended purpose and in a
technically flawless condition.
Only operate the equipment in a safety and hazard-conscious manner and with
all protective devices. Do not change or bypass any protective devices.
Before beginning work, check the effectiveness of the operator's controls and
protective devices.
Never operate the unit in explosive environments.
Supervision
Never leave equipment running without supervision!
3 Safety
100_0101_si_0005.fm 11
Maintenance
Regular maintenance work is required for a flawless and permanent functioning
of the equipment. Neglected maintenance reduces the equipment's safety.
The prescribed maintenance intervals must be strictly observed.
Do not use the equipment if maintenance or repairs are needed.
Faults
In the event of malfunctions, you must immediately switch the equipment off and
secure it.
Immediately rectify faults that can impair safety!
Have damaged or defective components replaced immediately!
You can find more information in the chapter Troubleshooting.
Spare parts, accessories
Only use spare parts from Wacker Neuson or such spare parts that are compa-
rable in the design system and quality of the original parts.
Only use accessories by Wacker Neuson.
Non-observance cancels out any liability.
Disclaimer
For the following violations, Wacker Neuson dismisses any liability for personal
injury or material damage:
Structural change.
Improper use.
Non-observance of this operator's manual.
Improper handling.
Using spare parts that do not originate from Wacker Neuson or are not com-
parable in the design system and quality of the original parts.
Using accessories that do not originate from Wacker Neuson.
Operator’s manual
Always keep the operator's manual readily available on the equipment or at the
place of application of the equipment.
If you should lose the operator's manual or require another copy, please contact
your Wacker Neuson contact partner or download the operator's manual from
the Internet (www.wackerneuson.com).
Hand over this operator's manual to every other operator or subsequent owner
of the equipment.
3Safety
12
100_0101_si_0005.fm
Country-specific regulations
Also, observe country-specific regulations, standards and guidelines for accident
prevention and environmental protection, such as dealing with hazardous sub-
stances and wearing personal protection equipment.
Supplement the operator's manual with additional instructions on taking opera-
tional, regulatory, national or generally applicable safety standards into consid-
eration.
Operator’s controls
Always keep the equipment's operator's controls dry, clean and free from oil and
grease.
Operator's controls, such as the ON/OFF switch, throttle control handles, etc.
may not be locked, manipulated or changed without permission.
Check for damage
Check the shutdown equipment at least once per shift for externally visible dam-
age and deficiencies.
Do not operate the equipment if damage or deficiencies are discernible.
Have damage and deficiencies rectified immediately.
3.2 Qualification of the operating personnel
Qualification of the operator
Only technically trained personnel may start and operate the equipment. In ad-
dition, the following conditions apply:
They are physically and mentally suitable.
They are trained in the independent operation of the equipment.
They are trained how to use the equipment in accordance with the intended
purpose.
They are familiar with the necessary safety devices.
They are authorized to operate equipment and systems independently ac-
cording to the standards of safety engineering.
They are appointed by the contractor or operator to independently work with
the equipment.
3 Safety
100_0101_si_0005.fm 13
Faulty operation
In the event of faulty operation, misuse or operation by untrained personnel, dan-
gers threaten the health of the operator or third parties as well as the condition
of the device or other material assets.
User responsibilities
The user must make the operator's manual available to the operator and ensure
that the operator has read and understood them.
Recommendations for work
Please observe the following recommendations:
Only work in a good physical condition.
Work attentively, especially at the end of working hours.
Do not work with the equipment when you are tired.
Perform all work calmly, cautiously and carefully.
Never work under the influence of alcohol, drugs or medication. Your vision,
reactivity and judgment may be impaired.
Work so that no third parties are harmed.
Make sure that there are no people or animals in the danger area.
3.3 Protection equipment
Working clothes
The clothing should be appropriate, i.e. tight fitting, but not cumbersome.
Generally, do not have any long hanging hair, loose clothing or jewelry (including
rings) during on construction sites. There is a risk of injury, for example from be-
ing snagged or pulled in on moving equipment parts.
Only wear flame-resistant working clothing.
Personal Protection Equipment
Use personal protection equipment in order to avoid injuries and health hazards:
Safety shoes.
Work gloves made from sturdy material.
Overalls made from sturdy material.
Protective helmet.
Ear protection.
Facial protection.
Eye protection.
3Safety
14
100_0101_si_0005.fm
Ear protection
With this equipment, it is possible to exceed the permissible, country-specific
noise limit (personal rating level). This is why you may have to wear ear protec-
tion under certain circumstances. You can find the exact value in the chapter
Technical data.
Work particularly cautiously and pay attention when wearing ear protection, as
your ability to hear noises, such as screams or signal tones, is restricted.
Wacker Neuson recommends always wearing ear protection.
3.4 Transport
Switch off the unit
Before transport, switch the equipment off and remove the plug from the plug re-
ceptacle. Allow the engine to cool down.
Transporting the equipment
Secure the equipment on the means of transport from tipping over, falling down
or sliding.
Lifting the unit
Serious risk of injury from falling equipment.
The unit does not have any lifting eyes or tie downs.
When lifting, secure the device against tipping over, falling or slipping, such as
when in a closed transport container.
Re-commissioning
Before re-commissioning, attach and fasten equipment, equipment parts, acces-
sories or tools that were dismantled for transport purposes.
Proceed only according to the operator's manual.
3.5 Operational safety
Explosive area
Never operate the unit in explosive environments.
3 Safety
100_0101_si_0005.fm 15
Work environment
Familiarize yourself with the work environment before beginning work. For exam-
ple, this includes the following points:
Obstacles in the work and traffic area.
Load-bearing capacity of the soil.
Necessary protection of the construction site, especially for the public trans-
port area.
Necessary protection of walls and ceilings.
Options available in the event of accidents.
Safety in the working area
If you work with the equipment, pay particular attention to the following points:
Pay maximum attention near drops or slopes. Risk of crashing.
No people may be in the working area.
Checks before starting work with the HMS
Check the following points before starting work:
Connection values of the drive motor.
Condition of the individual components.
Permissible combinations and connection links of the HMS.
Commissioning the HMS
Observe the safety instructions and warning notices on the drive motor as well
as those in the operator's manual.
Never operate equipment that is in need of maintenance or repairs.
Operate the HMS according to the operator's manual from the drive motor.
Stability
Always ensure good footing when working with the HMS. This especially applies
when working on scaffolding, ladders, uneven or slippery surfaces.
Beware of hot parts
Do not touch the hot vibrator head (component of HMS) during operation or
shortly thereafter. The vibrator head can become very hot and cause burns.
3Safety
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100_0101_si_0005.fm
Use caution with moving parts of the HMS
Keep hands, feet and loose clothing away from moving or rotating vibrator head
(component of HMS).
Do not use components of the HMS as a climbing aid or securing means
Never use the protection hose, power cable or other components of the HMS as
a climbing aid or securing means.
Protect the flexible shaft (component of the HMS)
Do not excessively bend or kink the flexible shaft.
Do not pull the flexible shaft over sharp edges.
If the flexible shaft has become jammed in the reinforcement, switch off the drive
motor and disconnect the flexible shaft from the drive motor. Then release the
clamped flexible shaft by carefully moving it back and forth.
Switch off the unit
Switch the equipment off and remove the plug from the plug receptacle in the fol-
lowing situations:
Before breaks.
When you are not using the equipment.
Before putting the equipment down, wait until it comes to a complete standstill.
Set the equipment down so that it cannot tip over, fall down or slip.
Storage
Set the equipment down so that it cannot tip over, fall down or slip.
Storage location
After operation, store the cooled equipment in a locked, clean, frost-protected
and dry location that is inaccessible to children.
Vibration load of the HMS
Vibration-induced long-term damage cannot be ruled out entirely during inten-
sive use of walk-behind drive motors.
Observe the respective statutory provisions and guidelines in order to keep the
vibrations to a minimum.
You can find information about the vibration load of the HMS in the chapter Tech-
nical Data.
3 Safety
100_0101_si_0005.fm 17
3.6 Safety when operating hand-held equipment
Working safely with hand-held equipment
While working, only hold the equipment by the handle intended solely for this pur-
pose.
Always keep the power cable behind and away from the drive motor and keep
the power cable away from the working area of the vibrator head.
Ensure that the air intakes and outlets are clear.
Setting down hand-held equipment properly
Carefully lay down the equipment. Do not throw the equipment on the floor or
from great heights. When thrown down, the equipment can injure other people
or even be damaged itself.
3.7 Safety when operating electrical equipment
Specific regulations for electrical equipment
Observe the safety instructions in the General safety instructions brochure from
the equipment's standard package.
Also observe the country-specific regulations, standards and directives for acci-
dent prevention in conjunction with electrical systems and equipment.
WARNING Read all safety instructions and information Failure to com-
ply with the safety information and instructions can cause electric shock, fire and
/ or serious injuries.
Save all safety information and instructions for the future.
3Safety
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100_0101_si_0005.fm
Electric power supply for electrical equipment of class rating II
Notice: The rated voltage can be found on the nameplate of your equipment.
You may only connect the equipment to electric power supplies if all device parts
can be found in a technically perfect condition. In particular, pay attention to the
following components:
Plug.
Power cable in its entire length.
Switch membrane of the on / off switch, if present.
Plug receptacles.
Electrical equipment of class rating II has a reinforced or dual insulation (protec-
tive insulation) and does not have a connection to the grounded conductor.
With a mains connection, at least one of the following safety devices must be
present at the point of connection:
Protective ground fault interrupter (GFI or GFCI).
Insulation monitor.
IT net.
Isolating transformer.
Notice: Observe the respective national safety standards!
Extension cable (accessories)
You may only operate the equipment with undamaged and tested extension ca-
bles!
You may only use extension cables with grounded conductors and a proper
grounded conductor connection to the plug and coupling (only equipment of
class rating I, see chapter Technical data).
You may only use tested extension cables that are suitable for construction site
use: Wacker Neuson recommends H07RN-F, H07BQ-F, a SOOW-cable or a
country-specific equivalent design.
You must immediately replace extension cables with damage (e.g. tears in the
casing) or loose plugs and couplings.
Cable drums and multi-pole plug receptacles must meet the same requirements
as extension cables.
Protect extension cable, multi-pole plug receptacles, cable drums and connec-
tion couplings from rain, snow or other forms of moisture.
3 Safety
100_0101_si_0005.fm 19
Completely unroll the cable drum (accessories)
Risk of fire if the cable drum is not completely unrolled.
Completely unroll the cable drum before operation.
Protect the power cable
Do not use the power cable to pull or lift the equipment.
Do not pull the plug of the power cable out of the plug receptacle by pulling the
cable.
Protect the power cable from heat, oil and sharp edges.
Have your Wacker Neuson contact partner immediately replace damaged power
cables or loose plugs.
Protect against moisture
Protect the equipment from rain, snow or other forms of moisture. Damage and
other malfunctions are possible.
Protect against excessively high or low temperatures
Protect the equipment against excessively high or low temperatures. The insula-
tion of live parts can otherwise be damaged.
You can find information about the permissible temperature range in the chapter
Technical data.
3.8 Safety when operating modular internal vibrators
Shoulder strap (accessory)
Wacker Neuson recommends using a shoulder strap.
You can find more information in the chapter Accessories.
3Safety
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100_0101_si_0005.fm
3.9 Maintenance
Maintenance work
Care and maintenance work may only be carried out insofar as it is described in
this operator's manual. All other work, such as the replacement of the power ca-
ble, must be performed by the Wacker Neuson contact partner in order to avoid
safety hazards.
You can find more information in the chapter Maintenance.
Disconnect from the electric power supply
Before performing maintenance jobs, you must remove the plug from the plug re-
ceptacle in order to disconnect the equipment from the electric power supply.
Cleaning
Always keep the equipment clean and clean it after every use.
Do not use any fuels or solvents. Explosion hazard!
Do not use any high-pressure washers. Water ingression can damage the unit.
With electrical equipment, there is a serious risk of injury from electric shock.
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